EP3137402B1

EP3137402B1 - Measuring device, system and method for measuring a wrapping force

Info

Publication number: EP3137402B1
Application number: EP15728169.2A
Authority: EP
Inventors: Mauro Cere'
Original assignee: Aetna Group SpA
Current assignee: Aetna Group SpA
Priority date: 2014-05-02
Filing date: 2015-04-30
Publication date: 2018-07-11
Anticipated expiration: 2035-04-30
Also published as: US9891120B2; WO2015166447A1; ES2689854T3; US20170052075A1; EP3137402A1

Description

The invention relates to devices and instruments for detecting and measuring a wrapping force of a film made of stretchable plastic material wrapped around a load by a wrapping machine. In particular, the invention relates to a measuring device applicable to a load and to a system and method which use such measuring device for detecting a wrapping or tightening tension or strength of the plastic film wrapped around a load.
The known, fixed or self-propelled, wrapping machines comprise an unwinding apparatus which supports a reel from which the plastic film is unwound for being wrapped around the load so as to form a series of strips or bands partially overlapped having a helical arrangement, thanks to the combination of the vertical movement of the unwinding apparatus and the relative rotation between the latter and the load. The load is typically composed by one or more products or objects grouped and arranged on a bench or vane or pallet.
In the self-propelled wrapping machines the unwinding apparatus is vertically mobile along a column mounted on a vehicle that is mobile around the load.
In the wrapping machines provided with a rotating table for supporting the load, the latter is rotated around a vertical axis, while the unwinding apparatus is vertically moved with alternated motion along a fixed column.
In the wrapping machines with horizontal rotating ring or rotating arm, the load remains static during the wrapping, while the unwinding apparatus is moved relatively to the load both in rotation around the vertical axis and in translation along the latter. For this purpose, the unwinding apparatus is fixed to a ring or to an arm, which are rotatably supported by a fixed structure of the machine so as to rotate around the load.
In the wrapping machines with vertical rotating ring, the load is horizontally moved through the ring, while the unwinding apparatus is fixed to the ring and rotated around a horizontal axis.
The unwinding apparatus typically comprises a couple of pre-stretching rollers arranged for unwinding the film from the roll and stretching or elongating the film, and one or more diverting or return rollers arranged for diverting the film toward the load. By suitably adjusting the difference between the rotation speeds of the pre-stretching rollers, it is possible to stretch by a given amount the film coming out from the unwinding apparatus.
The film stretching is generally expressed in percentage as the ratio between the film elongation (i.e. the difference between the final length of the stretched film and the original length) and the original length. Typically, the elongation imparted to the film is comprised between 50 and 400%.
By adjusting the rotation speed of the pre-stretching rollers it is also possible to vary the unwinding speed of the film from the reel, that is the speed of the film coming out from the unwinding apparatus.
The plastics film is stretched before being wrapped around the load as the stretching or elongation allows to best use the film and give to the latter physical-mechanical characteristics such as to make it more suitable to stand the forces acting on the load during the subsequent handlings and transport. In particular, when the stretching force ceases, the film elastic return causes a wrapping or blocking tension or force on the load, which ensures the containment of the latter.
The wrapping force of the film is an important operating parameter whose value strictly depends both on shape and arrangement of the products which are grouped on the pallet and on the products types themselves. The value of the wrapping force in fact has to be such as to ensure the stability and solidity of the wrapped load during all the handling and transporting steps thereof. In other words, the film wrapped around the load, when the latter is subjected to dynamic and/or physical stress, such as acceleration, vibration, temperature variations, etc., has not to loosen and/or to allow relative displacements of the products and/or a deformation and instability of same load. As a result of a strong deformation, the load can also collapse, consequently damaging the products and/or making impossible to handle the load afterward.
The wrapping force has to be therefore sufficiently high to ensure the wrapping stability, but not such as to crush and/or damage the products grouped on the pallet. In some cases, the above mentioned products have shape and composition (material, structure) such as to be easily deformable when too tightly wrapped by the film.
Finally, the values of the wrapping force has to be substantially constant along the whole perimeter of the load in order to not create torsional forces on the latter that could cause a deformation of the load.
The need to find a value of the film wrapping force which allows a correct and stable wrapping of the load without damaging the products or deforming the load, forces the manufacturers of wrapping machines and/or the final users to carry out preventive tests on the loads to be wrapped.
However such tests are particularly long and laborious. In fact, once identified the optimum value or range of values of the wrapping force for a particular type of product (form, structure, material) that are grouped to form a particular load (width, length, height), it is necessary to adjust each wrapping machine which has to wrap the such load, in order to obtain the desired value of the wrapping force by acting on the speed wrapping and/or the film stretching.
The wrapping force is measured by detecting the force required to detach the wrapped film from the load. Typically, a special measuring instrument is used for performing this measurement, which is previously wrapped by the film together with the load or subsequently inserted between the wrapping bands or strips of the film, the measuring instrument being rotated on itself by linearly moving it along a load wall.
Alternatively, the measuring instrument comprises a plate also inserted between the bands of the film and then detached from the load in a direction orthogonal to wall thereof. By measuring the force required to move the measuring instrument (for rotating or detaching it) with a dynamometer it is possible to calculate the tightening force of the film around the load. However, these fully manual measuring methods are long, laborious and subject to errors as these measuring methods are performed by an operator.
Furthermore, many wrapping tests have to be performed before obtaining the desired value of the wrapping force with a consequent waste of time and resources.
US 2010/300049 discloses a film wrapping machine wherein various operational conditions and data can be detected, determined, and subsequently utilized for diagnostic, operational performance, and safety characteristics, as well as for implementing improvements in operational performance so as to not only achieve optimal or predetermined performance characteristics but to also achieve economical usage of the wrapping or packaging film.
EP 1083126 relates to a stretch wrapping machine that employs a touch panel input device as input means for setting the film wrapping data into the controller. A display of the touch panel input device provides digital presentation of the information on set values of the film wrapping data or a machine failure. Wrapping conditions can be automatically computed simply by entering film wrapping data on the number of wraps on the load, the film overlap amount, the film wrapping tension of the film stretch ratio, etc. The wrapping machine further comprises a load detection unit for detecting a load, which is imposed on a film fed out from the feed roller onto an article. While constantly computing a difference between a measured value of the wrapping tension deriving from the detected value of the load and a set value of the wrapping tension as set by the input means, the number of feed roller rotations is feedback controlled in such a manner as to decrease the difference to zero.
US 4458467 discloses a tensioner assembly that pre-stretches a film web prior to unitizing a pallet load. The film web undergoes three stages of stretching by the tensioner assembly, which includes two driven rollers and a resiliently biased dancer roller. The dancer roller engages the film and maintains it under continuous tension loading as the pallet load rotates. An electrical control signal proportional to the angular position of the dancer roller is employed by a control circuit to vary the rotational speed of the pretensioner drive rollers. The film web is stretched in a first stage between a feedstock roll and the first drive roller. A second stage of stretching occurs between the first driven roller and the second driven roller. Finally, the film web undergoes a third stage of stretching between the second driven roller and the pallet load, with the web being maintained under tension at all times by the resiliently biased dancer roller.
An object of the invention is to improve the known measuring devices and the known systems and methods for measuring a wrapping force or tension of a film made of stretchable plastic material wrapped around a load.
Another object is to provide a measuring device associable with a load to be wrapped and a related measuring system and method, which allow to detect and measure in a fast, simple and precise manner a wrapping force exerted on the load by the wrapped film.
A further object is to provide a device, a system and a method that allow to detect and measure in real time during the wrapping process the wrapping force of the film on the load in any point thereof.
Another object is to carry out a modular measuring device, which is both associable and usable on any shaped and sized loads to be wrapped with film.
Another further object is to carry out a robust and reliable measuring device having a simple and economical manufacture.
In a first aspect of the invention there is provided a measuring device according to claim 1.
In a second aspect of the invention there is provided a measuring system comprising the measuring device of the first aspect and according to claim 10.
In a third aspect of the invention there is provided a measuring method according to the measuring system of the second aspect and according to claim 13.
The invention can be better understood and implemented with reference to the attached figures, which illustrate an exemplifying and non-limiting embodiment, wherein:

Figure 1 is a front perspective view of the measuring device according to the invention;
Figure 2 is a rear perspective view of the device of Figure 1;
Figure 3 is a rear perspective view, partially sectioned, of the device of Figure 1, showing a control unit;
Figure 4 is a plan view of the device of Figure 1;
Figure 5 is a section along the line V-V of Figure 4;
Figures 6 and 7 are respectively a perspective view and a front view of a supporting element for mounting the measuring device of the invention on a load;
Figure 8 is a perspective view of a measuring system of the invention comprising a plurality of devices of Figure 1 and associated to a load to be wrapped;
Figure 9 is an enlarged partial plan view of the system and the load of Figure 8;
Figure 10 is a perspective view of the measuring system of the invention applied to a load and to a wrapping machine with rotating table.

With reference to Figures 1 to 10, a measuring device 1 is shown according to the invention for detecting and measuring a tightening or wrapping force F of a film 50 made of stretchable plastic material that is wrapped around a load 100 by a wrapping machine 60.
The device 1 comprises a first angular element 2 elongated, associable to a portion of the load 100, one or more force sensors 10, for example two, fixed to the first angular element 2 mutually spaced apart along a longitudinal extending direction A of the first angular element 2, a second angular element 3 substantially elongated, that is fixed to, and supported by, said force sensors 10 and a control unit 5, connected to the force sensors 10 and arranged to receive from the latter ones a signal related to a wrapping force F exerted to the second angular element 3 by the film 50 wrapped around the load 100 and the device 1, fixed thereon prior the wrapping.
The first angular element 2 comprises a stiff metallic section bar, for example made of aluminum alloy, having an "L" cross section and formed by two first flat portions 21 substantially orthogonal to each other and joined at a first jointing edge 22.
The force sensors 10, for example two, are fixed to the first angular element 2 at and along the first jointing edge 22. For this purpose, the first jointing edge 22 has a flat outer face 22a that is arranged to receive the respective sensors force 10.
The second angular element 3 comprises a metal section bar, for example made of aluminum alloy, also having a "L" cross section and composed by two second flat portions 31 substantially orthogonal to each other and joined at a second edge junction 32. The second angular element 3 is fixed to the force sensors 10 along an inner face 32a of the second flat edge junction 32.
The force sensors 10 include, for example, respective load cells or equivalent force transducers, of known type and not described and illustrated in detail in the figures.
The device 1 further comprises fixing means 6, 7 for hooking the device to the load 100.
In the illustrated embodiment, the fixing means comprises a plurality of hooks 6 mutually spaced apart and fixed to longitudinal borders 21a of the first angular element 2 and flexible means 7 removably connected to the hooks 6 and wrappable around the load 100.
In particular, the hooks 6 are fixed substantially orthogonally to the longitudinal borders 21a. The flexible means 7 comprises elastic or non-stretchable belts that are fixed to the hooks 6 by elastic means.
The fixing means 6, 7 allows the device 1 to be fixed firmly to the load 100 in the desired position in which the wrapping force of the film is desired to be measured.
As shown in the figures, the shape of the measuring device 1, comprising two angular elements 2, 3, allows an easy and stable positioning thereof along the longitudinal edges 101 of the load 100. The measuring device 1 can also be positioned on a flat wall 102 of the load 100 by arranging the longitudinal borders 21a of the first angular element 2 facing the flat wall 102.
A supporting element 8 is also provided for associating the device 1 to the flat wall 102 and for facilitating and making stable its positioning. The supporting element 8 comprises a plate provided with a seat 18 adapted to be coupled with the longitudinal borders 21a of the first angular element 2.
The device 1 can be provided with connecting means of known type and not shown in the figures, which is positioned at the opposite ends of the first angular element 2 and which can be coupled in a reversible manner with respective connection means of another device 1. The connection means makes modular the device 1, allowing in this manner to connect in series a plurality of measuring devices 1, according to the size of the load 100, for example according to the length of the longitudinal edge 101.
The control unit 5 is fixed inside a cavity 35, which is carried out on one of the second flat portions 31 of the second angular element 3, and comprises means for electrically powering the force sensors 10, means for receiving and processing the signal received by the force sensors 10 and transmitting means for wireless transmitting the signal to an external receiving unit 45, i.e. a desktop or a laptop computer, a data mobile transceiver such as a tablet, a smartphone, etc.. The transmitting means can transmit in radio frequency by Wi-Fi or Bluetooth technology.
The control unit 5 is powered by batteries and includes a power button 15, which can be easily activated by the user.
With particular reference to Figures 8 to 10, the measuring system 40 of the invention arranged to detect and measure a wrapping force F of a film 50 of stretchable plastic material wrapped around a load 100, comprises one or more measuring devices 1, for example two in the illustrated embodiment, that are associated and fixed to the load 100 at an edge 101 and a flat wall 102 of the latter and an external receiving unit 45, arranged for receiving the signal transmitted by the measuring devices 1 and related to the wrapping forces 50 exerted by the wrapped film F on the load 100 and the measuring devices 1.
The measuring devices 1, suitably fixed to the pallet 100 before the wrapping process, are capable to detect and measure in real time during the wrapping of the film 50 the wrapping or tightening force that is exerted by the film at various points of the pallet 100, in which said devices 1 are positioned. In particular, each measuring device 1 transmits the two values of the wrapping force measured by the two force sensors 10.
The wrapping force F varies during the wrapping and assumes different values at different points of the load (longitudinal edges 101, flat walls 102).
Thanks to the measuring device 1 and the measuring system 40 of the invention is thus possible to measure accurately and precisely, in real time, during the wrapping of the load 100, the wrapping force F and to act in feedback on the wrapping machine 40. In particular, it is possible to change the operating parameters of the wrapping machine 60 in order to vary the wrapping force F exerted by the film 50 till to reach a predefined value of said wrapping force that guarantees stability and firmness of the wrapped load 100 and anyway such as to not deform and damage the products which compose the load.
The operating parameters of the wrapping machine 60 comprise an unwinding speed of the film 50 from an unwinding unit 61 of the wrapping machine, a stretching or elongating ratio of the film 50 and a relative rotation speed between an unwinding unit 61 of the wrapping machine 60 and the load 100.
In the shown embodiment, the wrapping machine 60 is, for example, of the type with rotating platform 63, which rotatably supports the load 100 to be wrapped. The machine 60 comprises a column 62, which slidably supports the unwinding unit 61. The latter is vertically moved with alternate motion and comprises a couple of pre-stretching rollers arranged to unwind the film from a reel and then stretch or elongate the film, and one or more diverting or return rollers arranged to divert the film towards the load 100. By suitably adjusting the difference between the rotation speeds of the pre-stretching rollers, it is possible to stretch by a set amount the film coming out from the wrapping apparatus. By adjusting the rotation speed of the pre-stretching rollers it is also possible to vary the unwinding speed of the film from the reel, i.e. the speed of the film coming out from the unwinding unit 61. The unwinding speed also depends on the rotation speed of the rotating platform 63
Thus, the measuring device 1 and the measuring system 40 of the invention allow in a fast, simple and automatic manner to have precise and accurate information about the values of the wrapping force F of the film 50 around the load 100 in the different critical points of the load 100, so as to verify the absence of values of wrapping or tightening force capable to damage the grouped products which compose the load and/or to verify the absence of torsional forces which could deform the load and affect the stability thereof.
The torsional forces on the load are generated, as known, by a wrapping force that is not uniform along the load perimeter, but is significantly variable at different points of said load.
In addition to this, the measuring device 1 and the measuring system 40 of the invention allow determining in an easy, fast and inexpensive manner the operating parameters of the wrapping machine 60 that are required to carry out an optimal wrapping of the load 100, according to shape and the dimensions thereof and according to shape and composition (material, structure) of the products.
The measuring method of the invention provides the use of one or more measuring devices 1 to detect and measure a wrapping force F of a film 50 made of stretchable plastic material wrapped around a load 100 by a wrapping machine 60 provided with a wrapping unit 61.
The method provides the following steps:

associating and fixing to the load 100 at least one measuring device 1 at one longitudinal edge 101 or at a flat wall 102 of said load 100;
wrapping the load 100 with the film 50;
detecting a signal transmitted by the measuring device 1 and related to a wrapping force F exerted by the wrapped film 50 on the load 100 and on the measuring device 1.

It is also provided to associate to the load 100 a plurality of measuring devices 1 fixed at the edges 101 and/or at flat walls 102 of the load 100 and to detect the respective signals transmitted by said plurality of measuring devices 1 and related to respective wrapping forces exerted on the measuring devices 1 by the film 50.
The method provides, during the detection of the signals related to the wrapping force, to modify the operating parameters of the wrapping machine 60 for varying the wrapping force F exerted by the film 50 till to reach a predefined wrapping value. The operating parameters comprise an unwinding speed of the film 50 from the unwinding unit 61 and/or a stretching ratio of the film 50 and/or a relative rotation speed between load 100 and unwinding unit.

Claims

Measuring device for detecting and measuring a wrapping force (F) of a film (50) made of stretchable plastic material that is wrapped around a load (100), characterized in that it comprises a first angular element (2), associable and fixable to an edge (101) and/or a flat wall (102) of said load (100), at least one force sensor (10) fixed to said first angular element (2), a second angular element (3), fixed to and supported by said force sensor (10) and a control unit (5) connected to said force sensor (10) and arranged to receive therefrom a signal relating to at least one wrapping force (F) exerted on said second angular element (3) by said film (50) that is wrapped around said load (100) and said measuring device (1).
Device according to claim 1, comprising a plurality of force sensors (10) that are fixed to said first angular element (2), spaced apart along a longitudinal extension direction (A), support said second angular element (3) and are connected to said control unit (5).
Device according to claim 1 or 2, wherein said first angular element (2) comprises two first flat portions (21) that are substantially orthogonal to each other and joined at a first jointing edge (22), said force sensor (10) being fixed to said first jointing edge (22), in particular to an flat outer face (22a) thereof.
Device according to any preceding claim, wherein said second angular element (3) comprises two second flat portions (31) that are substantially orthogonal to each other and joined at a second jointing edge (32), said second angular element (3) being fixed to said force sensor (10) at said second jointing edge (32), in particular at a flat inner face (32a) of said second jointing edge (32).
Device according to any preceding claim, comprising fixing means (6, 7) for removably attaching said device (1) to said load (100).
Device according to claim 5, wherein said fixing means comprise a plurality of hooks (6) spaced apart and fixed to longitudinal borders (21a) of said first angular element (2) and flexible means (7) connected to said hooks (6) and wrappable around said load (100).
Device according to any preceding claim, comprising at least one supporting element (8) for associating said device (1) to a flat wall (102) of said load (100).
Device according to any preceding claim, wherein said control unit (5) comprises means for electrically powering said force sensor (10), means for receiving and processing said signal received by said force sensor (10) and transmission means to wireless send said signal to an external receiving unit (45).
Device according to any preceding claim, wherein said force sensor (10) comprises a load cell or a force transducer.
System for detecting and measuring a wrapping force of a film (50) made of stretchable plastic material that is wrapped around a load (100), comprising at least one measuring device (1) according to any preceding claim, that is associated with and fixed to said load (100) at an edge (101) and/or a flat wall (102) of said load (100) and an external receiving unit (45), which is arranged to receive a signal transmitted from said measuring device (1) and relevant to a wrapping force (F) exerted by said wrapped film (50) on said load (100) and said measuring device (1).
System according to claim 10, wherein said external receiving unit (45) comprises one among fixed computer, laptop computer, data mobile transceiver.
System according to claim 10 or 11, comprising a plurality of measuring devices (1) fixed to edges (101) and/or flat walls (102) of said load (100) for detecting and measuring in real time wrapping forces exerted by said film in respective different points of said load (100).
Method for detecting and measuring a tightening force of a film (50) made of stretchable plastic material that is wrapped around a load (100) by means of a wrapping machine (60) provided with an unwinding unit (61), using at least one measuring device (1) according to any one of claims 1 to 9, comprising:
- associating and fixing said measuring device (1) to said load (100) at an edge (101) or a flat wall (102) of the latter;

- wrapping said load (100) with said film (50);

- detecting a signal transmitted by said measuring device (1) and related to a wrapping force (F) exerted by said wrapped film (50) on said load (100) and said measuring device (1).
Method according to claim 13, comprising associating to said load (100) a plurality of measuring devices (1) that are fixed at edges (101) and/or flat walls (102) of said load (100) and detecting respective signals transmitted by said plurality of measuring devices (1) and related to respective wrapping forces exerted by said film (50) on said measuring devices (1).
Method according to claim 13 or 14, comprising, after said detecting, modifying operating parameters of said wrapping machine (60) for varying said wrapping force (F) exerted by said film (50) until reaching a preset value of the wrapping force, in particular said operating parameters comprising an unwinding speed of said film (50) from said unwinding unit (61), a stretching ratio of said film (50), a relative rotation speed between said unwinding unit (61) and said load (100).